Endress ESE 607 DBG ES DIN User manual

OPERATING MANUAL
ESE 607 DBG DIN Article-No. 151202 / 156202
ESE 607 DBG ES DIN Article-No. 151212 / 156212
ESE 957 DBG ES DIN Article-No. 151214 / 156214

2ESE 607 / 957 DBG (ES) DIN Issued: February 2013
Manufacturer and publisher ENDRESS
Elektrogerätebau GmbH
Neckartenzlinger Str. 39
D-72658 Bempflingen, Germany
Tel.: + 49 (0) 71 23 / 9737 – 0
Fax: + 49 (0) 71 23 / 9737 – 50
Email: [e-mail]
www: http://www.endress-stromerzeuger.de
Document-No. E134021
Publication date February 2013
Copyright © 2013, ENDRESS Elektrogerätebau GmbH
This documentation and parts thereof are subject to copyright.
Any use or modification beyond the restrictions of the
Copyright Act is forbidden and subject to penalty without the
consent of ENDRESS Elektrogerätebau GmbH.
This applies in particular to copies, translations, microfilming,
as well as storage and processing in electronic systems.

Issued: February 2013 ESE 607 / 957 DBG (ES) DIN 3
Table of Contents
1 General information about this manual ............................................................7
1.1 Documentation and accessories ............................................................................. 8
1.2 Safety warning symbols .......................................................................................... 9
2 General safety regulations............................................................................... 11
2.1 Important safety warning ........................................................................................11
2.2 Intended use.......................................................................................................... 12
2.2.1 Foreseeable incorrect use or inappropriate handling ............................................. 13
2.2.2 Residual risks ......................................................................................................... 14
2.3 Operating personnel - Qualifications and Obligations ........................................... 17
2.4 Personal protective equipment.............................................................................. 17
2.5 Danger zones and work areas .............................................................................. 18
2.6 Signs on the generator .......................................................................................... 19
2.7 General safety warnings........................................................................................ 22
3 Power generator ESE 607 / 957 DBG (ES) DIN description...........................27
3.1 Views of the generator .......................................................................................... 27
3.1.1 Operating and engine side components................................................................. 28
3.1.2 Exhaust and generator side components............................................................... 29
3.1.3 Control panel components ..................................................................................... 30
3.1.4 Accessory components .......................................................................................... 31
3.2 Function and operating mode................................................................................ 32
4 Operating the ESE 607 / 957 DBG (ES) DIN ....................................................34
4.1 Transporting the generator .................................................................................... 34
4.2 Setting up the generator........................................................................................ 35
4.3 Refuelling the generator ........................................................................................ 36

4ESE 607 / 957 DBG (ES) DIN Issued: February 2013
Table of Contents
4.4 Starting the generator............................................................................................ 37
4.5 Switching the generator off.................................................................................... 41
4.6 Connecting up to consumers................................................................................. 42
4.7 Checking the protective conductor ........................................................................ 43
4.8 Monitoring the operating status using the multifunction display ............................ 44
4.9 Laying up the generator ........................................................................................ 48
4.10 Disposal................................................................................................................. 48
5 Using special fittings / accessories ................................................................50
5.1 FI protection switch ............................................................................................... 50
5.2 Insulation monitoring using E-MCS 4.0 (without switching off) ............................. 52
5.3 Maxdrive................................................................................................................ 53
5.4 Speed reduction at idle.......................................................................................... 54
5.5 Remote start device .............................................................................................. 55
5.6 External start device ............................................................................................. 57
5.7 Battery charge retention device............................................................................. 58
5.8 3-way fuel valve / Refuelling device ...................................................................... 60
5.9 Exhaust hose......................................................................................................... 63
6 Generator ESE 607 / 957 DBG (ES) DIN maintenance ...................................64
6.1 Maintenance plan .................................................................................................. 64
6.2 Maintenance work ................................................................................................. 65
6.2.1 Engine oil................................................................................................................ 65
6.2.2 Changing the starter battery................................................................................... 68
6.2.3 Replacing fuses...................................................................................................... 69
6.3 Checking the electrical safety................................................................................ 70

Issued: February 2013 ESE 607 / 957 DBG (ES) DIN 5
Table of Contents
List of illustrations
Figure 2-1: Signs on the generator.............................................19
Figure 3-1: Views of the generator .............................................27
Figure 3-2: Components on the operating and engine side .......28
Figure 3-3: Components on the exhaust and generator side .....29
Figure 3-4: Control panel components .......................................30
Figure 3-5: Standard accessories components .........................31
Figure 3-6: Components of the special accessories...................31
Figure 4-1: Pull on manually-operated choke.............................38
Figure 4-2: Standard design of operating panel .........................38
Figure 4-3: Connecting up consumers .......................................42
Figure 4-4: Check the protective conductor................................43
Figure 5-1: FI protection switch ..................................................51
Figure 5-2: Insulation monitoring using E-MCS 4.0....................52
Figure 5-3: Idle speed reduction press switch............................54
Figure 5-4: Remote start device with Harting plug .....................55
Figure 5-5: Remote start device with CAN plug .........................56
Figure 5-6: Connecting up an external start device....................57
Figure 5-7: Connecting up the battery charge retention device .58
Figure 5-8: Connecting up the battery charge retention device .58
Figure 5-9: Connecting up the battery charge retention device .59
Figure 5-10: 3-way fuel valve .....................................................60
Figure 5-11: Connecting up the exhaust hose............................63
Figure 6-1: Oil dipstick................................................................65
Figure 6-2: Changing the oil .......................................................66
Figure 6-3: Replacing the battery ...............................................68
Figure 6-4: Replacing a fuse ......................................................69
Figure 8-1: Generator dimensions..............................................75
7 Troubleshooting................................................................................................71
8 Technical Specifications ..................................................................................75

6ESE 607 / 957 DBG (ES) DIN Issued: February 2013
Table 2.1: Danger zones and work areas on the generator .......18
Table 2.2: Signs on the generator...............................................21
Table 4.1: Protective conductor test lamp...................................43
Table 5.1: FI protection switch test .............................................51
Table 5.2: Insulation monitoring without switching off.................52
Table 5.3: Insulation monitoring whilst running without switching
off ...............................................................................53
Table 5.4: 3-way fuel valve switch positions...............................60
Table 6.1: Generator maintenance plan .....................................64
Table 6.2: Location of the fuses..................................................69
Table 7.1: Problems during generator operation ........................73
Table 8.1: Generator technical data............................................76
Table 8.2: Ambient conditions for the generator .........................77
Table 8.3: Generator power reduction dependent on ambient
conditions...................................................................77
Table 8.4: Maximum line length of the distribution network as a
function of the cable cross-section.............................77
List of charts
General note: The illustrations in these operating instructions do not always
comply completely with the actual design, in particular with
regard to the colour, and are to be considered a representation of
basic principles.
We reserve the right to make modifications in terms of ongoing
technical development.
These instructions do not include technical modifications that
occurred after printing.
Table of Contents

General information about this manual
Issued: February 2013 ESE 607 / 957 DBG (ES) DIN 7
1 General information about this manual
These operating instructions must be read carefully and
understood before using the generator.
These operating instructions are intended to familiarise you with
the basic operation of the generator.
These operating instructions contain important information on
using the generator safely and appropriately.
Complying with this information helps to:
avoid hazards
reduce repair costs and downtime
increase the reliability and service life of the generator.
However, not only these operating instructions but also the laws,
regulations, guidelines, and standards applicable in the country
of use and at the site of operation must be observed.
These operating instructions only describe the generator
operation.
The operating manual for the engine is an integral
component of these instructions.
A copy of these operating instructions must be available to the
operating personnel at all times.

General information about this manual
Documentation and accessories
8ESE 607 / 957 DBG (ES) DIN Issued: February 2013
1.1 Documentation and accessories
In addition to these operating instructions, the following
documents are relevant for the generator:
operating instructions and maintenance instructions for the
engine (Briggs & Stratton Corporation)
Briggs & Stratton Service Germany (Briggs & Stratton
Corporation)
test protocol for the power generator
maintenance instructions for the battery
circuit diagram for the generator

General information about this manual
Safety warning symbols
Issued: February 2013 ESE 607 / 957 DBG (ES) DIN 9
1.2 Safety warning symbols
The safety warning symbol indicates that a source of danger
exists. The safety warning symbols used in the work area of
the machine/plant and the entire technical documentation
correspond to the Council Directive 92/58/EEC - Minimum
requirements for the provision of safety and/or health signs at
work.
General hazard warning
This warning symbol indicates activities where several causes
can lead to risks.
Potentially explosive materials
This warning symbol indicates activities during which there is an
explosive hazard, possibly with lethal consequences.
Dangerous electrical voltage
This warning symbol indicates that the danger of an electric
shock, possibly with lethal consequences, exists.
Toxic substances
This warning symbol indicates that danger from toxic substances,
possibly with lethal consequences, exists.
Warning of environmentally damaging substances
This warning symbol indicates that the environment could be
endangered, possibly with catastrophic consequences.
Hot surfaces warning
This warning symbol indicates that the danger of burns, possibly
with lasting consequences, exists.

General information about this manual
Safety warning symbols
10 ESE 607 / 957 DBG (ES) DIN Issued: February 2013
Notes

General safety regulations
Important safety warning
Issued: February 2013 ESE 607 / 957 DBG (ES) DIN 11
2 General safety regulations
This section describes the basic safety regulations covering
operation of the generator.
Whoever operates the generator or works with it must read this
chapter and comply with its regulations in practice.
2.1 Important safety warning
ENDRESS generators are designed to operate electrical
equipment with appropriate power output requirements. Other
applications can lead to injury to the operating personnel and to
damage to the generator as well as other damage to equipment.
The majority of injuries and damage to equipment can be
avoided if all instructions given in this manual and all instructions
attached to the generator are followed.
The generator must not be modified in any way. This can lead to
an accident occurring and damage to the generator as well as
devices.

General safety regulations
Intended use
12 ESE 607 / 957 DBG (ES) DIN Issued: February 2013
WARNING!
The following actions are not permitted.
operation in explosion-prone environments
operation in fire-prone environments
operation in confined areas
operation from a vehicle platform that has not been swung
out
operation without the necessary safety redundancies
operation in existing power supply networks
refuelling when hot
refuelling during operation
spraying with high-pressure cleaners or fire-extinguishing
equipment
removal of protective devices
incorrect vehicle installation
not observed maintenance intervals
failure to measure and test for early damage identification
omitted exchange of wearing parts
incorrectly performed maintenance or repair work
defectively performed maintenance or repair work
non-intended use
2.2 Intended use
The generator produces electricity in place of the power grid, in
order to supply a mobile distribution system.
The generator is only to be used outdoors within the indicated
voltage, output, and nominal rpm ranges (see nameplate).
You are also permitted to use it on a vehicle extension or
swivelling platform in both extended and swung out states,
providing that the air circulation is uninterrupted on all sides of
the alternator and that the exhaust gases are dispersed correctly.
This is especially relevant as access to the side with the
instrument panel and the side with the exhaust gas connection
must be unrestricted.
The method that will be used to install the generator on the
surface area of a vehicle requires written approval from the
distributor that supplied the generator.

General safety regulations
Intended use
Issued: February 2013 ESE 607 / 957 DBG (ES) DIN 13
The generator is not to be connected up to other energy
distribution systems (e.g. public power supply) or to other energy
generation systems (e.g. other generators).
The generator is not to be used in explosion-prone environments.
The generator is not to be used in fire-prone environments.
The generator must be operated according to the specifications
in the technical documentation.
Any non-intended use or any activity with the generator not
described in these operating instructions is considered forbidden
incorrect use and is outside the legal limits of the manufacturer‘s
liability.
2.2.1 Foreseeable incorrect use or inappropriate handling
Foreseeable incorrect use or inappropriate handling of the
generator nullifies the manufacturer‘s EC Declaration of
Conformity and automatically thereby the operating licence.
Foreseeable incorrect use or inappropriate handling include:
operation in explosion-prone environments
operation in fire-prone environments
operation in confined areas
operation from a vehicle platform that has not been swung out
operation without the necessary safety redundancies
operation in existing power supply networks
refuelling when hot
refuelling during operation
spraying with high-pressure cleaners or fire-extinguishing
equipment
safety equipment removal
incorrect vehicle installation
not observed maintenance intervals
failure to measure and test for early damage identification
omitted exchange of wearing parts
incorrectly performed maintenance or repair work
defectively performed maintenance or repair work
non-intended use

General safety regulations
Intended use
14 ESE 607 / 957 DBG (ES) DIN Issued: February 2013
2.2.2 Residual risks
The residual risks were analysed and evaluated before beginning
the design and planning of the generator using a risk analysis
tool.
Residual risks which cannot be avoided by implementing design
measures during the whole life cycle of the generator can be:
mortal danger
risk of injury
environmental hazard
material damages to the generator
material damage to other property
output and/or functionality restrictions
You can avoid existing residual risks by observing and following
these guidelines:
the special warning notices on the generator
the general safety instructions given in these operating
instructions
the specific warnings given in these operating instructions
The specific standing instructions (the relevant operational
conditions) issued by fire-brigades, civil defence and other
relief organisations

General safety regulations
Intended use
Issued: February 2013 ESE 607 / 957 DBG (ES) DIN 15
Mortal danger Mortal danger to persons from the generator can arise from:
incorrect use
inappropriate handling
missing protective devices
defective or damaged electrical components
fuel vapours
engine exhaust gases
an excessively large distribution network configuration
Risk of injury Risk of injury to persons from the generator can be caused by:
inappropriate handling
transport
hot components
a recoiling starter rope on the engine
Environmental hazards Environmental hazards involving the generator may be caused
by:
inappropriate handling
operating fluids (fuel, lubricants, engine oil, etc.)
exhaust gas emissions
noise emissions
fire hazard
leaking battery acid
Material damage to the
generator
Material damage to the generator may be caused by:
inappropriate handling
overloading
overheating
an excessively low/high oil level in the engine
non-compliance with the operating and maintenance
specifications
unsuitable operating fluids
unsuitable hoisting gear
Material damage to other
valuable equipment
Material damage to other valuable equipment in the operating
range of the generator can occur through:
inappropriate handling
over and/or undervoltage
incorrect installation in a vehicle

General safety regulations
Intended use
16 ESE 607 / 957 DBG (ES) DIN Issued: February 2013
Generator‘s performance or
functionality - Limitations
The generator‘s performance or functionality can be limited by:
inappropriate handling
inappropriate maintenance or repair work
unsuitable operating fluids
an installation altitude greater than 100 metres above sea
level
an ambient temperature exceeding 25°C
an excessively large distribution network configuration

General safety regulations
Operating personnel - Qualifications and Obligations
Issued: February 2013 ESE 607 / 957 DBG (ES) DIN 17
2.3 Operating personnel - Qualifications and Obligations
Only appropriately authorised personnel may work with or on the
generator.
The authorised operating personnel must:
be of age.
be trained in First Aid and be able to provide it.
be familiar with the accident prevention regulations and
generator safety instructions and be able to apply them.
have read the chapter „General safety regulations“.
have understood the contents of the chapter „General safety
regulations“.
know how to practically use and implement the contents of
chapter „General safety regulations“.
be trained and instructed according to the rules of conduct in
the event of malfunctions occurring.
have the physical and mental abilities to carry out his
responsibilities, tasks, and activities on the generator.
be trained and instructed in his responsibilities, tasks and
activities on the generator.
have understood the technical documentation concerning his
responsibilities, tasks and activities on the generator and be
able to implement these in practice.
2.4 Personal protective equipment
Personal protection equipment must be worn during all activities
at the generator described in these operating instructions:
hearing protection
protective gloves
hard hat
protective shoes
fireproof protective clothing (in areas where the danger of fire
is high)

General safety regulations
Danger zones and work areas
18 ESE 607 / 957 DBG (ES) DIN Issued: February 2013
2.5 Danger zones and work areas
The danger zones and work areas on the generator are
determined by the activities to be performed within the individual
life cycles:
Life cycle Activity Danger zone Work area
Transport in the vehicle Radius of 1.0 m none
by the operating
personnel
Radius of 1.0 m
Operation Setting up
Operating Radius of 5.0 m
Radius of 2.0 m
Service and
maintenance
Cleaning Radius of 1.0 m
Shutting down
Maintenance
Table 2.1: Danger zones and work areas on the generator

General safety regulations
Signs on the generator
Issued: February 2013 ESE 607 / 957 DBG (ES) DIN 19
2.6 Signs on the generator
These signs must be fitted on the generator and be kept in a
clearly legible condition:
Figure 2-1: Signs on the generator
1 Reference note - three-way valve 7 EMERGENCY-STOP
2 Nameplate 8 Fuel note
3 Reference note - noise emission 9 Reference note - Engine maintenance
4 Reference note - read operating
instructions
10 Reference note - no naked flames
11 Potential equalisation screw (earthing for an
optional FI)5 Cable extension
6 Abridged operating instructions
(inside cover)
12 Reference note - Hot surface

General safety regulations
Signs on the generator
20 ESE 607 / 957 DBG (ES) DIN Issued: February 2013
Sign Name
External refuelling
Nameplate
Reference note - noise
emission
Reference note - read
operating instructions
Cable extension
Short operating
instructions
Reference note -
EMERGENCY-STOP